Unitized welt sole



Sept. 1, 1970 J. J. FERREIRA UNITIZED WELT SOLE 2 Sheets-Sheet Filed NOV. 14, 1968 INVENTOR JOSEPH J. FERREIRA BY m ygiowgz ATTORNEYS P 1970 .1. J. FERREIRA uumzno wnw sous 2 Sheets-Sheet 2:

Filed Nov. 14, 1968 m ON INVENTOR JQSEPH J FERREIR BY am 317661500?! ATTORNEYS United States Patent O 3,526,046 UNITIZED WELT SOLE Joseph J. Ferreira, Raynham, Mass., assignor to Frank Noone Shoe Co., Inc., a corporation of Massachusetts Continuation-impart of application Ser. No. 683,978, Nov. 17, 1967. This application Nov. 14, 1968, Ser.

Int. Cl. A43b 13/12 US. Cl. 3630 21 Claims ABSTRACT OF THE DISCLOSURE A shoe bottom assembly having an outsole and heel filler with plastic material surrounding the periphery of the outsole and lying immediately forward of the heel filler. A complete shoe may be formed by placing the outsole and heel filler in a mold, placing an assembled shoe upper against the outsole and then injecting fluent plastic material from one side of the mold into the crevice between the upper and the outsole to bond the plastic material both to the shoe bottom assembly and to the assembled shoe upper.

This application is a continuation-in-part of my application Ser. No. 683,978, filed Nov. 17, 1967, now abandoned.

Injection molding of wear surfaces is a commonplace practice in the shoe industry.

Some prior developments described in my issued patents involve the placement of a leather outsole in a mold before an injection molding step. Plastic is injected through a preformed opening in the outsole to form a molded midsole and welt to simulate the appearance of a conventional shoe having a leather outsole.

The present invention represents a departure from my previous techniques in that it eliminates piercing of the outsole to provide an opening for the introduction of the injected plastic materials; and, it avoids the injected plastic midsole which formerly permitted proper distribution of the liquid plastic material throughout the welt area during the injection step. By eliminating the plastic midsole, comfort of the finished shoe is significantly improved by restoration of outsole flexibility with a corresponding reduction in stiffness and weight.

Various aspects of this invention include the sub-combination of shoe bottom elements that are initially placed in the mold before the actual molding step; the completed shoe bottom assembly either with or without the assembled shoe upper bonded thereto; and, the related methods performed in the manufacture of finished shoes and shoe bottom assemblies.

The novel assemblage of elements for the shoe bottom assembly includes an outsole, preferably made of leather or leather simulating material, that extends from the foreportion of the shoe rearwardly beyond the heel breast line which is defined by a transverse plane projected through the forward edge of the heel in the completed shoe. Secured to the rear portion of the outsole that extends behind the heel breast line is a transverse enlargement or heel filler which depends from the underside of the outsole. In the preferred form of the invention, the heel filler has an exposed arcuate upper surface which is stepped to provide maximum surface area for adhesion of the plastic material injected therearound and increased adherence between the components of the completed shoe bottom assembly. If desired, a heel top lift of leather or other suitable material may be secured to the heel filler. The side portions of the outsole member are cut away in the vicinity of the heel breast line to facilitate the proper flow of plastic material through the mold cavity.

When completed, the shoe bottom assembly includes the 3,526,046 Patented Sept. 1, 1970 aforementioned outsole and heel filler elements as well as a molded plastic body in the form of a closed loop surrounding the periphery of the shoe bottom assembly with a portion extending transversely across the forward edge of the heel filler beneath the breast line of the outsole to positively lock the heel filler in place. Other important features which are preferred but not essential to the invention are that the plastic material has portions lying both above and below the heel filler to prevent vertical separation or delamination of the assembled components.

The present invention also involves the method of making a shoe by flowing plastic material into a cavity formed by the crevice between the assembled shoe upper and the outsole as well as by directing the flow of plastic material forwardly and rearwardly of the heel filler.

The principal object of this invention is to provide a shoe bottom assembly which is flexible, lightweight, attractive and durable throughout extended periods of wear. The durability of the unit enhanced by the body of molded plastic material which simulates both the welt surface and the peripheral edges of the sole and heel of a conventional finished shoe. Durability is also increased by positively locking the rear portion of the outsole and the heel filler within the plastic material to prevent relative separation. Longitudinal and lateral displacement of the outsole is prevented by attaching the heel filler to the outsole and providing a transverse interlocking plastic retaining portion forwardly of the heel filler. Vertical displacement of the heel filler is provided by having plastic material both above and below portions of the heel filler. Such a construction provides for maximum bonding surfaces between the plastic material and the assembled shoe upper to increase the strength of the bond as well as provide a weathertight seal.

Numerous other advantages are enjoyed by this invention which will be further understood by reference to the appended drawings and the following description.

FIG. 1 shows an exploded view of an assem'bled shoe upper, heel and sole assembly, and mold elements used to manufacture footwear in accordance with the invention;

FIG. 2 is an enlarged transverse sectional view taken through the mold and the assembled shoe components, showing the plastic material injected into the crevice formed by the assembled shoe upper and the elements of the heel and sole assembly;

FIG. 3 is a cross-sectional view taken transversely through the forward portion of the outsole along the line 33 of FIG. 2; I

FIG. 4 is a transverse view similar to FIG. 3, but taken along the line 4-4 of FIG. 2 through the rear portion of the outsole; and

FIG. 5 is a perspective illustration of the molded plastic material apart from the heel and sole assembly solely for purposes of illustration.

A completed shoe according to the invention may be produced by bringing together the components shown in FIG. 1, and then injecting a charge of fluent plastic material into the mold to unite the assembled units.

The mold assembly includes a base plate 2 and a pair of transversely movable side members 3. Each side member 3 has an interior vertical wall which is suitably lined and textured to produce a molded impression resembling the vertical side surfaces of a conventional welted shoe. Welt plates 4 are attached to the side members 3 and may be formed with the reverse impression of the upper surface of a leather Welt.

Base plate 2 has alignment pins 5 adapted to contact the peripheral side edges of an outsole to maintain a slight spacing between the outsole and the interior vertical walls of the mold side members 3.

As shown in FIGS. 1 and 2, the heel and sole assembly, generally designated by the numeral 6, includes an outsole 8 and a heel filler formed by elements 28 and 30 which constitutes a transverse enlargement affixed to the rear portion of the outsole with a heel top lift 50 attached to the underside of the heel filler element 30.

An assembled shoe upper 7 of conventional construction has been shown for illustrative purposes.

Prior to the injection molding step, the heel and sole assembly 6 is placed against the upper surface of the base plate 2 where it will be held in proper position by the alignment pins 5. The side members 3 of the mold assembly 1 are moved inwardly to the position shown in FIG. 1 and the assembled shoe upper 7 is moved into contact with the inner edges of the welt plates 4. Plastic material is then injected from sprue 20 formed in the mold base plate 2 into the cavity formed by the mold assembly 1, heel and sole assembly 6 and assembled shoe upper 7.

Plastic material entering through the sprue 20 fiows in a clockwise direction as viewed in FIG. 1 to enclose the peripheral edges and upper marginal area of the forward portion of the outsole 8 as well as rearwardly in a counter-clockwise direction along the peripheral edge and upper marginal area of the outsole until it reaches the vertical opening 26 formed by the inwardly cut portion of the outsole. At this opening, the plastic material divides into two streams, one of which fiows transversely beneath the outsole 8 to fill the void forward of the heel filler elements 28 and 30, while the other stream passes rearwardly where it will surround the heel filler elements 28 and 30 until the cavity defined by the lower marginal surface of the shoe upper has been filled. The arcuate path followed by the plastic material around the rear portion of the shoe permits a relatively unobstructed flow which provides uniform distribution of the plastic material.

Once the entire cavity is filled by plastic material, a conventional telltale senses the completion of the injection molding operation and stops the flow of plastic to the sprue 20. The plastic material is then allowed to set sufiiciently before the mold is opened for withdrawal of the completed shoe.

Although polyvinyl chloride is the most suitable plastic material presently available, any elastomeric organic polymer, either natural or synthetic, which is capable of being injection molded can be used. Upon completion of the injection molding step, the plastic material will harden to form a unitary body generally of the configuration illustrated in FIG. with a closed loop which surrounds the peripheral edges of the heel and sole assembly components. The innermost portion 11 is inclined inwardly and downwardly due to its adhering conformance to the lower marginal area of the shoe upper. A transverse retaining portion 15 of the plastic body will lie forwardly of the heel filler to form the heel breast portion of the completed shoe.

Some of the details of construction of the shoe and its various elements are shown in the sectional views of FIGS. 2 through 4. The particular shoe upper shown in these figures is illustrative of a Goodyear welt shoe construction. Its fabrication involves the adhesion of a plyrib 40 to the insole 42. Normally, such a plyri-b is spaced inwardly approximately 5 of an inch from the peripheral edge 44 of the insole but this distance may be increased to approximately V of an inch in the area of the insole located forward of the heel breast line 46 in order to increase the surface area to which the plastic material may adhere. Behind the heel breast line, such marginal spacing is not necessary since there is sufficient bonding area without this modification. The upper leather is then lasted and secured to the insole 42 by stitching the marginal portion of the upper to the plyrib 40.

A conventional filler layer 48 of sponge rubber, ground cork or other suitable material may then be placed within the boundaries of the plyrib 40.

The assembled shoe upper 7 which in the disclosed embodiment includes the insole 42 and filler layer 48 is moved into association with the mold assembly 1 so that the leather upper abuts firmly against the welt-forming portions 4 of the mold, and the lower extremity of the plyrib 40 lies in contacting relationship with the upper surfaces of the heel and sole unit 6.

Several important features of the invention involve the manner in which the heel and sole unit 6 is constructed and arranged. As best shown in FIG. 1, the outsole 2 of this unit is cut to form an opening or passageway 26 in the vicinity of the heel breast line. This opening permits the plastic material to flow downwardly and form the transverse retaining portion 15 which defines the heel breast line. The heel filler which is formed by the superposed annular elements 28 and 30 is of stepped construction to allow the flow of plastic material around the rear peripheral portion of the heel while providing a maximum bonding area between the plastic material and the heel filler. This is done by making the element 28 smaller than the element 30 and configuring each of these to expose a U-shaped upper surface which will lie in direct contact with the plastic. As further precaution to prevent separation of the plastic material from the heel filler, the heel toplift 50 does not extend to the rear edge of the cavity, so that the plastic material will lie both above and below the heel filler element 30. This, of course, prevents vertical separation between these elements.

The horizontal thickness of the plastic material along the peripheral side edge of the outsole 8 is preferably only about of an inch. Injection molding procedures sometimes leave small voids in areas of such reduced thickness, particularly at the lowermost edges thereof. In order to avoid the total rejection of a shoe if such voids occur, the shoe bottom portion 2 of the mold is beveled at its upper marginal surface so that the injected plastic material will form a downwardly extending projection around the periphery of the shoe. Voids in the plastic, if any, will be found in this area. The downwardly extending projection may be removed by buffing after the mold ing step.

The foregoing description has dealt with many details of my improved shoe construction and method which contribute to the satisfactory production of a shoe having an injection molded welt and peripheral band. Many of these features may be used in conjunction with other shoe manufacturing processes. This invention is not limited to the specific embodiment disclosed, since it may assume various forms within the spirit of the claims which follow.

What is claimed is:

1. A shoe bottom assembly having sole and heel portions separated by a heel breast line, said assembly comprising an outsole having a rear portion extending behind the heel breast line, an enlargement on the rear portion of the outsole, and a unitary molded body of plastic material extending around the outsole forward of the heel breast line and lying immediately forward of the transverse enlargement to prevent longitudinal displacement of the outsole, said unitary molded body having an upper marginal surface formed to simulate a leather welt.

2. A shoe bottom assembly according to claim 1 'wherein the enlargement is a heel filler attached beneath the outsole.

3. A shoe bottom assembly according to claim 2 in combination with an assembled shoe upper which is bonded to the outsole by the unitary molded body.

4. A shoe bottom assembly according to claim 2 having a heel toplift attached to and underlying the heel filler.

5. A shoe bottom assembly according to claim 4 wherein the unitary molded body underlies a portion of the heel filler and overlies an upper marginal edge portion of the heel toplift.

6. A shoe bottom assembly according to claim 2 wherein the unitary molded body includes a closed loop which encloses the periphery of the assembly.

7. A shoe bottom assembly according to claim 6 wherein the portion of the closed loop forward of the heel breast line overlies the upper marginal surface of the outsole.

8. A shoe bottom assembly according to claim 7 in combination with an assembled shoe upper which is bonded to the outsole by the unitary molded body.

9. A shoe bottom assembly according to claim 6 having a heel toplift permanently secured to the heel filler, the unitary molded body including a portion overlying an upper marginal surface of the heel toplift and underlying a portion of the heel filler.

10. A shoe bottom assembly according to claim 2 wherein the heel filler has a portion of its upper surface in direct contact with the unitary molded body.

11. A shoe bottom assembly according to claim 10 wherein the portion of the upper surface of the heel filler which contacts the unitary molded body extends arcuately around the rear portion of the assembly.

12. A shoe bottom assembly according to claim 10 wherein the heel filler comprises a pair of superposed elements, each of: which has an arcuately shaped portion of its upper surface extending around the rear portion of the assembly and contacting the unitary molded body.

13. A shoe bottom assembly according to claim 10 wherein the unitary molded body is in direct contact with at least a portion of the lower surface of the heel filler.

14. A shoe bottom assembly according to claim 10 in combination with an assembled shoe upper which is bonded to the outsole by the unitary molded body.

15. A shoe bottom assembly comprising an outsole having its peripheral edge and upper marginal surface covered by a molded body of organic polymeric material configured to simulate a welt and peripheral side edges of a welted shoe construction, said molded body having a peripheral ridge depending below without overlying the bottom marginal surface of the outsole.

16. A heel and sole assembly adapted for incorporation into a shoe bottom by plastic molding techniques, said assembly comprising an outsole, a heel filler attached to and underlying the rearward portion of the outsole, and a heel toplift attached to and underlying the heel filler, with the periphery of the outsole being cut inwardly throughout the heel outline which lies rearwardly of a point in the region above the forward edge of the heel toplift to provide an opening leading from above the outsole to a zone forward of the heel filler and a flow passage for plastic material around the rear of the outsole.

17. A heel and sole assembly according to claim 16 wherein the entirety of the heel filler is wider than the overlying outsole and narrower than the heel toplift thereadjacent.

18. A heel and sole assembly according to claim 16 wherein the heel filter comprises at least two stacked elements each having exposed arcuate upper marginal surfaces.

19. A heel and sole assembly according to claim 16 wherein the heel filler lies rearwardly of the forward edge of the heel toplift a distance sufficient to permit the presence of an injection molded transverse retaining portion of plastic material in the space lying rearwardly of the forward edge of the heel toplift, forwardly of the heel filler, and between the outsole and the heel toplift.

20. A heel and sole assembly adapted for incorporation into a shoe bottom by plastic molding techniques, said assembly comprising an outsole, a heel filler attached to and underlying the rearward portion of the outsole, and a heel toplift attached and underlying the heel filler, said heel filler lying rearwardly of the forward edge of the heel toplift a distance sufficient to permit the presence of an injection molded transverse retaining portion of plastic material in the space lying rearwardly of the forward edge of the heel toplift, forwardly of the heel filler, and between the outsole and the heel toplift.

21. A heel and sole assembly according to claim 20 wherein a side portion of the outsole is cut in the region above the forward edge of the heel toplift to provide a vertical opening leading from above the outsole to a zone forward of the heel filler.

References Cited UNITED STATES PATENTS 1,282,874 10/1918 Krohn et a1.

2,165,427 7/ 1939 Vigorith et al 36-245 2,246,480 6/ 1941 Weidner 36-31 X 2,255,177 9/1941 Lyness.

2,456,659 12/ 1948 Weidner 36-30 2,703,461 3/1955 Fox 36-34 3,116,566 1/1964 Ferreira 36-30 3,177,598 4/1965 Ferreira 36-30 ALFRED R. GUEST, Primary Examiner 

